Power system and method

ABSTRACT

The application is directed to a power system that may be provided in a portable form and operationally configured for use at a work site as a single source of electric power, hydraulic power and pneumatic power for work site operations. In regard to hydraulic fracturing stimulation of a wellbore, the power system is operationally configured as the source of hydraulic power for transportable pumping units of a fracturing operation and for hydraulic power tools, as the source of pneumatic power for pneumatic power tools and as the source of electric power for electric power tools and electronic equipment at a well site.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Patent ApplicationSer. No. 62/486,858, filed on Apr. 18, 2017, the content of which ishereby incorporated by reference in its entirety. This application alsoclaims benefit of U.S. Provisional Patent Application Ser. No.62/489,468, filed on Apr. 25, 2017, the content of which is herebyincorporated by reference in its entirety. This application also claimsbenefit of U.S. Provisional Patent Application Ser. No. 62/505,066,filed on May 11, 2017, the content of which is hereby incorporated byreference in its entirety. This application also claims benefit of U.S.Provisional Patent Application Ser. No. 62/617,164, filed on Jan. 12,2018, the content of which is hereby incorporated by reference in itsentirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

The application relates generally to a system providing hydraulic powerand/or pneumatic power and/or electric power as a permanent installationat a work site or as a portable system for temporary operation at a worksite.

Hydraulic fracturing, sometimes called “fracing” or “fracking” is aprocess for increasing the flow of oil or gas from a well. Frackingtypically involves pumping specific types of liquids into a well, underpressures that are high enough to fracture the rock forminginterconnected fractures that serve as pore spaces for the movement ofoil and natural gas to a wellbore. Known hydraulic fracturing equipmentused in oil and natural gas fields typically includes a large number ofequipment and components, for example, blenders, high-volume fracturingpumps, monitoring units, material tanks, hoses, pipes, electronicssystems, lighting, power units and backup power units required for knownday and/or night fracturing operations.

Known fracturing operations require considerable operationalinfrastructure, including large investments in fracturing equipment andrelated personnel. Notably, standard transportable pumping units requirelarge volumes of diesel fuel and extensive equipment maintenanceprograms. Typically, each transportable pumping unit on site requireseither a tractor with a power take off (“PTO”) or an alternative engineto start the pumping unit engine. At the time of this application, inthe United States of America each tractor requires at least one U.S.Department of Transportation (“DOT”) driver. Drivers must operate on thehighways, hauling equipment on and off work sites. A potentially largefleet of tractor trailers, e.g., semi-trailer trucks, necessary forfracturing operations can cause work site congestion and may impact thelocal community in terms of traffic congestion and road-surface wear andtear. A large fleet of tractor trailers also often times results in toomany people being on location at a well site. While some drivers mayhave other on-site responsibilities, other personnel have little to dobut sit in the cabin of the tractor during fracturing operations. A wellsite can be a dangerous place and having twenty (20) to fifty (50)non-essential personnel on location often poses safety issues andincreases operating expenses.

With average fracturing operations requiring as many as fiftytransportable pumping units operating concurrently, the work site area,or “footprint”, required to accommodate such fracturing operations islarge and the operational infrastructure required to support thesefracturing operations is extensive. Greater efficiency in fracturingoperations is desired.

SUMMARY

The present application is directed to a power system including aplatform supporting a primary power source, a hydraulic power supplysystem, an electric power supply system and a pneumatic power supplysystem thereon, wherein the primary power source is the exclusive sourceof power for the hydraulic power supply system, electric power supplysystem and the pneumatic power supply system.

The present application is also directed to a system for stimulating theproduction of hydrocarbons from subterranean formations at a well siteincluding (1) one or more high pressure fracturing pumps operationallyconfigured to inject fluid into one or more wells at the well site; and(2) a portable power system including a platform supporting a primarypower source, a hydraulic power supply system, an electric power supplysystem and a pneumatic power supply system thereon; wherein the primarypower source is the exclusive source of power for the hydraulic powersupply system, electric power supply system and the pneumatic powersupply system; and wherein the hydraulic power supply system is theexclusive power source for the one or more high pressure fracturingpumps.

The present application is also directed to a modular power systemincluding a first modular platform supporting a first modular primarypower source, a hydraulic power supply system including a first modularhydraulic power unit, an electric power supply system including one ormore modular transformers and a pneumatic power supply system thereon,wherein the primary power source is the exclusive source of power forthe hydraulic power supply system, electric power supply system and thepneumatic power supply system.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a prior art schematic plan view of a known fracturing spreadas of the time of the filing of this application.

FIG. 2 is a simplified plan view of an embodiment of a power deliverysystem layout employing the power system for fracturing operations.

FIG. 3 is a simplified plan view of an embodiment of a power deliverysystem layout employing the power system for fracturing operations.

FIG. 4 is a simplified plan view of an embodiment of a power deliverysystem layout employing the power system for fracturing operations.

FIG. 5 is a simplified plan view of an embodiment of a power deliverysystem layout employing the power system for fracturing operations.

FIG. 6 is a simplified illustration of an embodiment of a chassis of apower system of this application.

FIG. 7 is a simplified illustration of an embodiment of a chassis of apower system of this application.

FIG. 8 is a simplified illustration of an embodiment of a chassis of apower system of this application.

FIG. 9 is a simplified illustration of an embodiment of a chassis of apower system of this application.

FIG. 10 is a simplified illustration of an embodiment of a chassis of apower system of this application.

FIG. 11 is a simplified illustration of a power system of thisapplication.

FIG. 12 is a top perspective view of an embodiment of a power system ofthis application.

FIG. 13 is a top perspective view of an embodiment of a skid member ofthe power system of FIG. 12.

FIG. 14 is a bottom perspective view of the skid member of FIG. 13.

FIG. 15 is a top perspective view of an embodiment of a wall panel frameof the power system of FIG. 12.

FIG. 16 is a top perspective view of an embodiment of a wall panelassembly of the power system of FIG. 12.

FIG. 17 is a top sectional view of an embodiment of the power system ofFIG. 12.

FIG. 18 is a back side sectional view of the power system of FIG. 12.

FIG. 19 is a front side view of the power system of FIG. 12.

FIG. 20 is a view of the inner surface of the front side of FIG. 19.

FIG. 21 is a back side view of the power system of FIG. 12.

FIG. 22 is a view of the inner surface of the back side of FIG. 21.

FIG. 23 is a right side view of the power system of FIG. 12.

FIG. 24 is a view of the inner surface of the right side of FIG. 23.

FIG. 25 is a left side view of the power system of FIG. 12.

FIG. 26 is a view of the inner surface of the left side of FIG. 25.

FIG. 27 is a perspective view of a door handle of the power system ofFIG. 12.

FIG. 28 is an illustration of a removable enclosure being installed ontoa skid member of a power system of this application.

FIG. 29 is a perspective view of an exemplary generator set for use aspart of a power system of this application.

FIG. 30 is a perspective view of an exemplary hydraulic power unit foruse as part of a power system of this application.

FIG. 31 is a simplified flowchart exemplifying operation of operablecomponents of an embodiment of a power system of this application.

DETAILED DESCRIPTION

The Figures described above and the written description of specificstructures and functions below are not provided to limit the scope ofthe invention. Rather, the Figures and written description are providedto teach persons skilled in the art to make and use the invention forwhich patent protection is sought. The skilled artisan will appreciatethat not necessarily every feature of a commercial embodiment of theinvention is described or shown. Also, it is to be understood that thepresent invention is not limited to particular embodiments. It is alsoto be understood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting.

Approximating language, as used herein throughout the specification andclaims, may be applied to modify any quantitative representation thatcould permissibly vary, without resulting in a change in the basicfunction to which it is related. Accordingly, a value modified by a termor terms, such as “about”, is not limited to the precise valuespecified. In some instances, the approximating language may correspondto the precision of an instrument for measuring the value. The terms“first,” “second,” and the like, herein do not denote any order,quantity, or importance, but rather are used to distinguish one elementfrom another.

As used herein, the terms “may” and “may be” indicate a possibility ofan occurrence within a set of circumstances; a possession of a specifiedproperty, characteristic or function; and/or qualify another verb byexpressing one or more of an ability, capability, or possibilityassociated with the qualified verb. Accordingly, usage of “may” and “maybe” indicates that a modified term is apparently appropriate, capable,or suitable for an indicated capacity, function, or usage, while takinginto account that in some circumstances, the modified term may sometimesnot be appropriate, capable, or suitable. For example, in somecircumstances, an event or capacity can be expected, while in othercircumstances, the event or capacity cannot occur. This distinction iscaptured by the terms “may” and “may be”, or “can” or “can be”.Furthermore, the use of relational terms, such as, but not limited to,“top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,”“side,” and the like are used in the written description for clarity inspecific reference to the Figures and are not intended to limit thescope of the invention. As used herein, any references to “oneembodiment” or “an embodiment” or “another embodiment” means that aparticular element, feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodiment.The appearances of the phrase “in one embodiment” in various places inthe specification are not necessarily referring to the same embodiment.

As used in this specification and the appended claims, the phrases “dataacquisition and control center,” “data van,” “frac van” and like phrasesrefer to a computerized central command center to control all or atleast some critical well site equipment while monitoring, recording andsupervising the fracturing treatment. As understood by the skilledartisan, a “data van” is typically located at the site of hydraulicfracturing and may include one or more video monitors and/or livingquarters. The combination of various equipment used for hydraulicfracturing of a well is typically referred to in the industry as a“spread,” “fracturing spread” or “frac spread” and such may be usedherein interchangeably. General details regarding hydraulic fracturingand the equipment used can be found in a large number of referencesincluding, for example, U.S. Pat. No. 3,888,311, entitled “HydraulicFracturing Method,” incorporated herein by reference in its entirety.Herein, the term “stimulation” generally refers to the treatment ofgeological formations to improve the recovery of liquid and/or gashydrocarbons. As understood by the skilled artisan, “SMART technology”refers to Self-Monitoring Analysis and Reporting Technology used toprevent computer hard drive errors.

The phrase “transportable pumping unit” may be used interchangeably withthe phrases “fracturing pump” and “frac pump,” which herein suitablyincludes a trailer, absent a tractor, housing an engine, transmission,high pressure pump (typically a Triplex pump or Quintuplex pump),hydraulic system, power end lubrication, packing lubrication and allnecessary valves and controls for operation of the frac pump asunderstood by the skilled artisan. As understood by the skilled artisan,fracturing pumps pressurize fracturing fluid, e.g., water, propane, orother suitable media, typically combined with proppant) prior toinjection of the pressurized fluid into a wellbore to fracture theunderlying formation. Herein, a plurality of frac pumps in use at a wellsite may be referred to collectiviely as a “frac pump sub-system.”Examples of commercially available frac pumps for use as part of thisapplication include, but are not necessarily limited to the FT-2251Trailer Mounted Fracturing United available from Stewart & Stevenson,L.L.C., Houston, Tex., U.S.A.; Triplex and Quintuplex frac pumpsavailable from Freemyer Industrial Pressure L.P., Fort Worth, Tex.,U.S.A.; the Q10 Pumping Unit available from Halliburton Energy Services,Inc., Houston, Tex., U.S.A., and the 2700 high-pressure frac pump unitavailable from Baker Hughes Incorporated, Houston, Tex., U.S.A. Asunderstood by the skilled artisan, the acronym “ISO” refers to theInternational Organization for Standardization, Geneva, Switzerland.Herein, a “power system” may also be referred to as a “power assembly,”“power pack assembly,” “power pack,” “power unit assembly,” “powersource assembly” or “power supply assembly.” The terms “mobile,”“portable” and “transportable” may both be used to describe an item,object, system or assembly discussed herein as being readily movablefrom one physical location to another. As understood by the skilledartisan “DNV” certification standards refer to those certificationstandards provided by DNV GL, an international accredited registrar andclassification society headquartered near Oslo, Norway. Herein, thephrase “revolutions per minute” may be shortened to “rpm.” Herein, theterm “horsepower” may be shortened to “hp.” Herein, the term “Hertz” maybe shortened to “Hz.” Herein, the term “megapascal” may be shortened to“MPa.” Herein, the phrase “pounds per square inch” may be shortened to“psi.” Herein, the phrase “liters per second” may be shortened to “L/s.”Herein, the phrase “cubic feet per minute” may be shortened to “cfm.”Herein, the phrase “cubic meters per minute” may be shortened to “cmm.”Herein, the phrase “barrels per minute” may be shortened to “bpm.”Herein, “ASTM” refers to standards developed or defined by ASTMInternational, West Conshohocken, Pa., U.S.A.

In one aspect, the application provides a fixable or mobile power systemincluding a hydraulic fluid delivery system for powering a frac pumpsub-system, the mobile power system being effective to reduce the numberof vehicles, equipment and/or personnel needed at the well site duringoperations, and/or reduce costs, improve efficiency of overalloperations, save time and delay caused by equipment failure andmaintenance, reduce the number of drivers and operators needed, improvesafety, reduce vehicle emissions, and combinations thereof. The powersystem may also include a pneumatic power supply and at least oneelectrical generator and at least one PTO for powering items such ashydraulic power tools. The power system of this application lowerscapital expenditures (“CAPEX”) and operating expenditures (“OPEX”).

In another aspect, the application provides a fixable or portable powersystem effective as the source of hydraulic, pneumatic and electricpower of a frac spread during fracturing operations. The power system isoperationally configured to power all lighting and the control buildingor data van for an entire well site. The power system is alsooperationally configured to provide backup power for auxiliaryelectrical needs.

In another aspect, the application provides a portable hydraulic powersystem including a primary power source in the form of an engineincluding a first PTO for delivery of hydraulic fluid to one or morefrac pumps and a second PTO for powering hydraulic power tools.

In another aspect, the application provides a system for minimizing thefootprint of a frac spread used during a hydraulic fracturing operation.The application also provides a method of minimizing the footprint of afrac spread by replacing known frac spread equipment with the powersystem of this application.

In another aspect, the application provides a power system having asingle source of compressed air, electric power and pressurizedhydraulic fluid for powering frac pumps, the power source being portableto and from various locations including, but not limited to oilfieldwell sites. The power system may employ SMART technology and telemetryeffective to enhance maintainability and operability of the powersystem, and in addition to field-viewing capabilities, provide fullremote-viewing capabilities, e.g., remote diagnostics, location trackingand performance monitoring via one or more remote control centers.

In another aspect, the application provides a power system having aninternal combustion engine as a power source for hydraulic power,pneumatic power and electric power at a work site including, but notnecessarily limited to a well site.

In another aspect, the application provides a novel design for aportable power system, including an electric power supply systemoperationally configured to generate electricity to power electricalpower items and equipment such as lights, power tools, air compressors,and a data van at a field site. The power system also includes ahydraulic power supply system for driving hydraulic power tools and fracpumps and a pneumatic power supply system for driving pneumatic powertools and operating as an air supply.

In another aspect, the application provides a process for powering fracspread equipment via a portable power system operationally configured toprovide pneumatic power, hydraulic power and electric power. The processincludes providing a power source having a primary power source, ahydraulic power supply system, an electric power supply system and apneumatic power supply system. The hydraulic power supply system isoperationally configured to provide remote start capabilities tomultiple hydraulic fracturing pumps simultaneously, thus eliminating theneed for tractors in the field, as well as multiple equipment operatorsto start the hydraulic fracturing pumps. The electric power supplysystem provides all of the electrical requirements at a well site,eliminating the need to manage multiple assets at the well site. Thepneumatic power supply system provides pneumatic power to handle mostwell site requirements from pneumatic tools used by mechanics,specialize pneumatic tools used on wellheads and wireline applicationsand provides general air at a well site, eliminating the need for amechanics truck and/or a rental compressor.

In another aspect, the application provides a method of powering one ormore frac pumps at a well site using a single power system as describedherein.

In another aspect, the application provides a method of circulatinghydraulic fluid amongst a plurality of frac pumps in a manner effectiveto start each frac pump at a desired time relative to the start time ofone or more other frac pumps in use for a hydraulic fracturingoperation. The circulation of hydraulic fluid may be closed loop andinclude hydraulic fluid filters.

In another aspect, the application provides a fracturing system,comprising a power system operationally configured to (1) deliverhydraulic power to a frac pump sub-system via a closed loop feed, thefrac pumps being operationally configured to deliver pressurizedfracturing fluid into at least one wellbore, under high pressureconditions sufficient to increase the downhole pressure of the wellbore,to exceed that of the fracture gradient of the solid matter surroundingthe wellbore; (2) provide electricity to frac spread equipment and otheritems requiring electric power for operation via at least one electricgenerator; and (3) provide pneumatic power to frac spread equipment andother items requiring pneumatic power.

In another aspect, the application provides a hydraulic fracturingsystem for stimulating oil or gas production from a wellbore during afracturing operation, including (1) one or more frac pumps fordelivering fracturing fluid into the wellbore; and (2) a power system influid communication with each of the frac pumps in a closed loop feed,the power system being operationally configured to provide hydraulicpower to each of the frac pumps for purposes of starting each of thefrac pumps for operation. The power system is further operationallyconfigured to provide hydraulic power to hydraulic power tools,electricity to fracturing operation equipment requiring electric powerfor operation and pneumatic power to equipment requiring the same. Thehydraulic fracturing system may also include a system control unitoperationally configured to control parameters of the one or more fracpumps and the power system.

In another aspect, the application provides a method of hydraulicfracturing stimulation of a wellbore comprising: (1) providing a fracpump sub-system and a power system in fluid communication with the fracpump sub-system; (2) powering the power system; (3) delivering hydraulicfluid from the power system to the frac pump sub-system to start thefrac pump sub-system; (4) once the frac pump sub-system is powered on,pumping fracturing fluid into a wellbore at a primary flow rate; and (5)monitoring the hydraulic fracturing using various controls on-siteand/or remotely.

In another aspect, the application provides a hydraulic fracturingsystem effective to simplify the power-delivery mechanism for poweringtransportable pumping units and/or reduce the number of vehicles at awell site and/or reduce the amount of personnel and the amount ofequipment at a well site during fracturing operations.

In another aspect, the application provides a mobile power system with ahydraulic fracturing fluid delivery system for controlling the pumpingof high pressure fracturing fluid into an underground wellbore at a wellsite, the mobile power system being transportable between multiple wellsites. In one suitable embodiment, the mobile power system comprises aprimary power source, one or more pump assemblies in fluid communicationwith one or more transportable pumping units and one or more electricalpower sources for providing electrical power to fracking equipment allon a single mobile platform such as a support skid or modular supportskid.

In another aspect, the application provides a mobile power systemoperationally configured to provide power for one or more fracturingpumps, one or more light sources, one or more control centers includingone or more data acquisition control centers, one or more hydraulicpower tools, one or more pneumatic power tools, and combinationsthereof.

In another aspect, the application provides a process for extractinghydrocarbons from a reservoir rock formation by a hydraulic fracturingoperation, comprising the step of introducing a hydraulic fracturingtreatment fluid into a subterranean formation at a pressure sufficientto form or to enhance at least one fracture within the subterraneanformation. The fracturing treatment fluid is pumped into at least onewellbore in the subterranean formation by a plurality of frac pumps thatare powered by a common power system, i.e., a common power source.

In another aspect, the application provides a frac spread having amobile power system as the sole source of hydraulic power for the fracspread and as a source of electric power and/or pneumatic power for thefrac spread. In another embodiment, the mobile power system may be thesole source of electric power and/or pneumatic power for the fracspread.

In another aspect, the application provides a hydraulic fracturingsystem including a frac spread having a mobile power system as the solesource of hydraulic power for the frac spread and as a source ofelectric power and/or pneumatic power for the frac spread. In anotherembodiment, the mobile power system may be the sole source of electricpower and/or pneumatic power for the frac spread.

In another aspect, the application provides a scalable power systemoperationally configured for (1) less demanding operations such asgeneral fluid pumping operations and pump down operations, (2) fluidoperations of high demand such as fracturing operations and emergencydewatering operations, and (3) fluid operations employing difficult orchallenging fluids of high viscosity.

In another aspect, the application provides a portable power systemincluding a hydraulic power source, an electric power source, apneumatic power source driven by a common primary power source of thesystem.

In another aspect, the application provides a power system including aninternal combustion engine operationally configured as a power sourcefor hydraulic power, pneumatic power and electric power at a work site.

In another aspect, the application provides a power system including anenclosure housing a primary power source, a hydraulic power source, anelectric power source and a pneumatic power source therein. Thehydraulic power source, electric power source and pneumatic power sourceare each driven or powered exclusively by the primary power source. Theenclosure is operationally configured to provide access to outlets incommunication with each of the hydraulic power source, electric powersource and pneumatic power source.

In another aspect, the application provides a portable or mobile powersystem including a hydraulic power supply system, an electric powersupply system and a pneumatic power supply system on a single platformdriven by a common internal combustion engine located on the platform ofthe power system.

In another aspect, the application provides a system for stimulating aformation, the system including (1) a source of fracturing fluid incommunication with the formation; (2) a portable power system includinga platform supporting a primary power source, a hydraulic power supplysystem, an electric power supply system and a pneumatic power supplysystem thereon, wherein the primary power source is the exclusive sourceof power for the hydraulic power supply system, electric power supplysystem and the pneumatic power supply system; and one or more highpressure fracturing pumps in fluid communication with the source offracturing fluid; (3) wherein the hydraulic power supply system is theexclusive power source for the one or more high pressure fracturingpumps; and (4) wherein one or more high pressure fracturing pumpspressurize fracturing fluid for flowing said fracturing fluid into theformation.

In another aspect, the application provides a modular power system forassembly as desired including a first modular platform supporting afirst modular primary power source, a hydraulic power supply systemincluding a first modular hydraulic power unit, an electric power supplysystem including one or more modular transformers and a pneumatic powersupply system thereon, wherein the primary power source is the exclusivesource of power for the hydraulic power supply system, electric powersupply system and the pneumatic power supply system. The modular powersystem may include one or more additional modular platforms forsupporting different operable components of the power system. Inaddition, one or more operable components may be supported on fixedplatforms at one or more particular locations.

As a point of reference, a typical frac spread employed at the time ofthis application may include various types of equipment, for example:(1) one or more slurry blenders to mix the fracking fluids; (2) anynumber of transportable pumping units typically located on transportableplatforms such as trailers pulled by tractors, the pumping unitsincluding high-pressure, high-volume pumps such as triplex or quintuplexpumps for pumping facturing fluid into a well; (3) monitoring equipment;(4) fracturing fluid tanks; (5) proppant storage tanks; (6) one or morechemical additive units; (7) high-pressure treating iron; (8)low-pressure flexible hoses; and (9) various meters and gauges. Atypical frac spread as known to the skilled artisan is depicted in thesimplified diagram of FIG. 1. As shown, a well site of about 14,164.0square meters (about 3.5 acres) can be quite congested in terms ofequipment and manpower. It is not unusual for about fifty (50) or morepersons (see symbol 11) to be present at a well site. When factoring insupport crews, there may be about seventy (70) or more persons 11present at a typical well site during fracturing operations.

Looking at FIG. 1 in more detail, the formation of each fracture (oreach “stage”) of a typical well 10 may require the injection of hundredsof thousands of gallons of fluid under high pressure supplied by one ormore frac pumps 12, which are normally mounted on trucks or tractors assuch are often referred to in the industry. Typically, the tractorsdelivering the frac pumps 12 remain at the well site throughouttreatment of a well 10. Typically, tractors are backed into positionside by side providing a series of frac pumps 12 in a row. Very often,frac pumps 12 are aligned in series in two opposing rows aligned inopposing rows, often referred to as a “right hand pump bank” and a “lefthand pump bank.” Suitably, the right hand and left hand pump banks arealigned on opposing sides of a centralized manifold 14 as shown inFIG. 1. As understood by persons of ordinary skill in the art offracking, the manifold 14 is designed to convey fluid from each of thefrac pumps 12 to a flow line 15 that is fluidly connected to the well10. In known operations, fluid and additives are blended in one or moreblenders 13 and taken by the manifold 14 to the intake or suction of thefrac pumps 12. Proppant storage vessels 16 and liquid storage vessels 17may be used for maintaining a supply of materials during fracturingoperations. Monitoring, recording and supervising the fracturingoperation may be performed in a control center such as a data van 18.Quality control tests of the fluid and additives may be performed in aseparate location or structure 19 before and during well treatments.Fuel for prime movers of the pumps may be stored in tanks 20.

It is common in hydraulic fracturing operations to fracture a well withten to twenty stages of fracturing treatment. The total amount of fluidpumped under high pressure may be as high as five million gallons ormore. Depending on the particular fracturing operation at a well site,fracturing equipment can be operated across a range of differentpressures and injection rates that are specific to a particular well 10.On the high end of the spectrum, the pressure used for hydraulicfracturing may be as high as 103421250 pascal (15,000 psi) and theinjection rate could be as much as 15501.7 liters (130.0 barrels) perminute.

Accordingly, the present application is drawn to a power system, systemand method effective to minimize the overall footprint at a well site byminimizing manpower, reducing fuel costs and minimizing the amount ofequipment employed at a well site during fracturing operations, whichalso serves to reduce travel costs for transporting equipment to andfrom a well site. In one aspect, the invention provides a closed loophydraulic system for powering frac pumps at a well site. In anotheraspect, the invention provides a system effective to activate each fracpump via a common power system serving as a common hydraulic fluidsource for the frac pumps of the system. In another aspect, theinvention provides a single portable power supply for providing (1)hydraulic power to (a) frac pumps and (b) hydraulic power tools and (2)electric power to equipment and other items requiring electric power foroperation. In other words, the frac pumps of the present system utilizea common source of hydraulic power to start the frac pumps as opposed tousing individual tractors to start each of the frac pumps as currentlyknown in the art of fracturing operations. As understood by the skilledartisan, the configuration of the power system described herein may bealtered to meet one or more particular hydraulic and/or electrical powerrequirements and/or specifications.

With attention to FIG. 2, in one embodiment the present system 10 mayinclude a single fixable or portable power system 100 that isoperationally configured to supply hydraulic power and electrical powersimultaneously to frac spread equipment at a well site for fracturingoperations. Suitably, the power system 100 is operationally configuredto (1) supply hydraulic power to a single transportable pumping unit ora bank of transportable pumping units (hereafter “frac pumps 105”), (2)supply hydraulic power to one or more hydraulic power tools 108, (3)supply pneumatic power to one or more pneumatic power tools 111 viaconduit 112 or as a general air supply and (4) supply electric power tovarious frac spread equipment, e.g., a data van 110, one or morelighting towers 115 as well as other equipment or items requiringelectric power. The power system 100 may supply hydraulic power,pneumatic power and electric power simultaneously—including, in oneembodiment, the supplying of hydraulic power via multiple PTOs. In thealternative, the power system 100 may supply for asynchronous operationof hydraulic power and electric power—including asynchronous operationof hydraulic power via multiple PTOs.

Turning to FIG. 3, in another implementation the invention may include asystem having a single portable power system 100 that is operationallyconfigured to (1) supply hydraulic power to two or more banks of fracpumps 105, e.g., a right hand pump bank 105 and a left hand pump bank106, (2) supply hydraulic power to one or more hydraulic power tools108, (3) supply pneumatic power to one or more pneumatic power tools 111via conduit 112 by discharging air or as a general air supply, and (4)supply electrical power to various frac spread equipment, e.g., a datavan 110, one or more lighting towers 115 as well as other equipment oritems requiring electric power. In still another embodiment, a righthand pump bank may be powered via a first power system and a left handpump bank may be powered via a separate second power system. Forexample, as shown in FIG. 4, a system of this application may include afirst power system 100 that is operationally configured to (1) supplyhydraulic power to one or more frac pumps, e.g., a left hand pump bank106, (2) supply hydraulic power to one or more hydraulic power tools108, (3) supply pneumatic power to one or more pneumatic power tools 111via conduit 112 or as a general air supply and (4) supply electricalpower to various frac spread equipment, e.g., a data van 110, one ormore lighting towers 115 as well as other equipment or items requiringelectric power. In this embodiment, the system may also include a secondpower system 101 that is operationally configured to (1) supplyhydraulic power to one or more different frac pumps, e.g., a right handpump bank 105, (2) supply hydraulic power to one or more hydraulic powertools 108 and (3) supply pneumatic power to one or more pneumatic powertools 111 via conduit 112 or as a general air supply. As shown in FIG.5, the second power system 101 may also supply electrical power tovarious frac spread equipment such as one or more lighting towers 115 asdesired or otherwise demanded according to operation requirements.

As seen in FIG. 2, a suitable power system 100 lies in fluidcommunication with each of the frac pumps 105 in a closed loopconfiguration via at least a fluid conduit or fluid conduit assembly 117that is effective to deliver hydraulic fluid, a.k.a., “hydraulic oil” or“working fluid” from one or more hydraulic fluid storage reservoirs toeach of the frac pumps 105 for pump activation and return the hydraulicfluid back to the one or more hydraulic fluid storage reservoirs of thepower system 100 via a similar return flow line 121. As shown, the powersystem 100 may also lie in fluid communication one or more hydraulicpower tools 108 in a closed loop configuration via a separate fluidconduit or fluid conduit assembly 118 effective to deliver hydraulicfluid to one or more hydraulic power tools 108 and return the hydraulicfluid back to a storage reservoir of the power system 100 via a similarreturn flow line 122. As such, a power system 100 of this applicationmay include a primary hydraulic PTO and a secondary hydraulic PTO.Likewise, the power system 100 may be operationally configured tosimultaneously generate electricity to power one or more items ofequipment via an electrical line assembly 119 comprised of one or moreelectrical conduits. In another embodiment, the power system 100 mayserve as a transfer pump operationally configured to convey hydraulicfluid to one or more downstream locations, e.g., convey hydraulic fluiddeliverable to the frac pumps 105 and/or the one or more hydraulic powertools 108 downstream to one or more downstream locations in addition toor in place of returning hydraulic fluid via the return flow lines 121,122.

Suitable fluid conduit assemblies 117, 118 and return flow lines 121,122 may include, but are not necessarily limited to combinations orstrings of sectional fluid conduit members and valves in fluidcommunication with the power system 100. One suitable sectional conduitmember may include, but is not necessarily limited to stainless steelpipe, flexible hydraulic hose (rated for the maximum pressure of thehydraulic circuits), and combinations thereof. Suitable valves include,but are not necessarily limited to isolation valves. Suitable isolationvalves include, but are not necessarily limited to control valves asunderstood by the skilled artisan. As discussed below, isolation valvesmay be operated manually and/or remotely with the aid of a controllingdevice affixed to the isolation valve, e.g., a pneumatic actuator or anelectric motor. One commercially available isolation valve for useherein includes, but is not limited to single and double solenoidoperated valves under the trade name VIKING XTREME® commerciallyavailable from Parker Hannifin Corporation, Cleveland, Ohio, U.S.A.

As shown in the simplified illustration of FIG. 2, frac pumps 105 aretypically set up in line left to right whereby sectional fluid conduitmembers are interconnected via fittings, connectors and isolation valves103 in a manner effective to operationally control the flow of hydraulicfluid to each of the frac pumps 105. As recognized by persons ofordinary skill in the fracking industry, this type of interconnecting offrac pumps 105 via a fluid conduit assembly 117 is often referred to as“daisy chaining.” In one particular embodiment, the conduits, connectorsand isolation valves may be of the quick disconnect type as understoodby persons skilled in the art fluid conduit connectors. Also, althoughnot necessarily required, the sectional fluid conduit members may be ofsubstantially equal length and diameter allowing for ease of use of anyspare sectional fluid conduit members anywhere along the hydraulicsub-system.

In regard to the delivery of electric power, the electrical lineassembly 119 may include those types of electrical conduits commonlyused in fracturing operations. Suitable, electrical lines for use hereinmay include, but are not necessarily limited to common electrical cord,flexible impact resistant electric cable, flexible impact resistantelectric wiring, extension variations of each, and combinations thereof.One suitable electrical line may include flexible electric cable havingan abrasion resistant outer jacket.

A suitable power system 100 of this application is provided as aportable module type assembly having a primary power source and aplurality of secondary power sources. With attention to FIG. 6, onepower system 100 may include a main support framework or chassis 200operationally configured to house the remaining component parts andequipment of the power system 100 on a chassis floor 201 therein. Tothis end, one suitable chassis 200 may include a box type frameworkincluding a planar bottom side 202 providing for a substantially levelorientation atop of one or more substantially level support surfacessuch as bare ground, a floor, a roof of a structure, a trailer bed orother platform such as a tandem axle chassis, a concrete platform orwooden platform or pallet. In one embodiment, the bottom side 202 may bedefined by the bottom most perimeter framework of the chassis 200including a raised floor 201 as shown in FIG. 6. In another embodiment,the chassis 200 may include a solid wall type member wherein the innersurface of the wall type member forms the floor 201 and the outersurface forms the bottom side 202 of the power system 100. In stillanother embodiment, the bottom side 202 may include a wall type memberhaving one or more holes there through, e.g., for ventilation, drainageof fluids, for weight reduction, bolting or otherwise securing thechassis 200 to a support surface via one or more fasteners, etc. Thebottom side 202 of the framework of the chassis 200 may also include oneor more holes there through for purposes of bolting down or otherwisesecuring the chassis 200 to a support surface via one or more fasteners.For example, in one implementation the power system 100 may bepermanently mounted to a flatbed trailer or the like. In still anotherembodiment, the floor 201 may be comprised of a grid type surface or thelike effective to minimize the weight of the chassis 200.

As seen in FIG. 6, in one embodiment the chassis 200 may beoperationally configured for portability, for example, operationallyconfigured to be lifted for transport via one or more types of liftingequipment including, but not necessarily limited to mechanical liftssuch as various types of forklifts, overhead cranes, hoists, andcombinations thereof. For example, the chassis 200 may include one ormore lifting type contact surfaces (1) upper openings or pockets 204and/or (2) lower openings or pockets 205 on one or more sides of thechassis 200 for receiving individual forks of a forklift, or other typeof lift, in a manner effective to move or transport the power system100. In another embodiment as seen in FIG. 7, a chassis 200 may includea single upper opening 206 and/or a single lower opening 207 on one ormore sides of the chassis 200 for receiving forks of a forklift, orother type of lift, in a manner effective to transport the power system100. In another embodiment, the lower openings 205 or 207 may beprovided as cutout sections as shown in FIGS. 8 and 9. It is furthercontemplated that any combination of the upper and lower openings orpockets described above may be implemented as desired on a particularchassis 200. Although not limited for use under any specifiedconditions, the upper openings 204 and 206 may be effective for use whenthe lower openings 205 or 207 are blocked off or otherwise inaccessible,e.g., if the power system 100 is set partially within a hole or restingon a flatbed trailer that has side walls or rails preventing use of thelower openings 205 or 207. In addition to lifting, each of the openingsdiscussed above may also be used for the purpose of tying down orotherwise securing a chassis 200 during transport or use.

Turning to FIG. 10, in still another embodiment, a chassis 200 mayinclude elongated spacers or risers 209, legs, feet or the like alongthe bottom of the chassis 200 for raising the bottom of the chassis 200up apart from a support surface providing room for forks of a forklift,or other type of lift, dolly or the like to extend below the chassis 200in a manner effective to move the chassis 200 (see FIG. 10). As furthershown in FIG. 10, the upper part 203 of the chassis 200 may also includeone or more lifting type contact surfaces in the form of one or morelift eyes 210, handles, hook members, or the like for lifting andtransporting the power system 100. In one particular embodiment, theupper part 203 of the chassis 200 may include a dual point lift in theform of lift eyes 210 on opposing sides of the chassis 200. The chassis200 may also include lift eyes 210 on each side. Persons of ordinaryskill in the art will appreciate that in still another embodiment achassis 200 may include ISO corner fittings and twist locks similar asused on freight containers and the like for purposes of lifting andtying down the chassis 200. Suitable corner fittings and twist locks arecommercially available from sources including, but not necessarilylimited to TANDEMLOC, Inc., Havelock, N.C., U.S.A. As understood by theskilled artisan, at the time of this application other commercialsources of corner fittings and/or twist locks may be found via the WorldWide Web at www.Alibaba.com. In still another embodiment, the frameworkof the chassis 200 may itself be used for lifting and/or transportpurposes.

It is further contemplated that the chassis 200 may include casters forpurposes of moving the power system 100 across support surfaces withoutthe aid of a mechanical lift. In such embodiment, ISO container casterssuch as those commercially available from TANDEMLOC, Inc. may be usedfor mobilization of the power system 100 by attaching the casters to theISO corner fittings of the chassis 200. As shown in the simplifiedexample of FIG. 10, the chassis 200 may be provided as an open seethrough type of framework. In another embodiment, the chassis 200 mayinclude one or more removable and/or permanent side walls, panels orhinged doors, e.g., lockable doors using rust-resistant pinned hinges,as desired or otherwise required per rules or regulations of aparticular jurisdiction, effective as a housing for enclosing at leastpart of the chassis 200. In still another embodiment, the chassis 200may include a drag bar with skid plates.

The chassis 200 is suitably constructed from one or more materialsincluding but not necessarily limited to those materials resistant tochipping, cracking, excessive bending and reshaping as a result ofozone, weathering, heat, moisture, other outside mechanical and chemicalinfluences, as well as various impacts and other loads placed on thechassis 200. Although the chassis 200 is not necessarily limited to anyone particular material of construction, the chassis 200 is suitablyconstructed from one or more materials durable enough to support about13,607.8 kg (30,000.00 pounds) or more during transport and/or operationwithout failing. In one particular embodiment, the chassis 200 complieswith the DNV 2.71 and/or DNV 2.73 certification standards. Furthermore,the chassis 200 may be built to scale according to anticipatedoperational demands and/or the size and/or quantity and/or arrangementof operable components provided as part of the power system 100.Typically, the more horsepower required the larger, and heavier, thepower system 100. For fracturing operations, the upper end power system100 may include a weight of about 45,359.2 kg (about 100,000.0 pounds).

For fracking operations, suitable chassis 200 materials of constructionmay include one or more metals. Suitable metals include, but are notnecessarily limited to aluminum, steel, titanium, and combinationsthereof. In one particular embodiment, the chassis 200 may beconstructed from stainless steel. In another particular embodiment, thechassis 200 may be constructed from mild steel. A metal chassis 200 maybe fabricated from individual framework materials, e.g., section membersor plank type members similar as other metal building materials and beassembled via bolts, welds, and combinations thereof as understood bythe skilled artisan. In another embodiment, a chassis 200 may comprisesmaller box type frame sections secured together. In still anotherembodiment, a complete chassis 200 or individual component partscomprising a chassis 200 may be produced via 3D printing or machined viacomputer numerical control (“CNC”).

For fracking operations, the chassis 200 side walls, panels and hingeddoors employed may be constructed from metals, plastics, rubbers,fibre-reinforced plastics, woods, acrylic glasses, and combinationsthereof. Suitable metals include, but are not necessarily limited toaluminum, steel, titanium, and combinations thereof. One suitable steelincludes galvanized sheet steel. Suitable plastics include, but are notnecessarily limited to polyvinyl chloride (“PVC”), polyvinylidenefluoride (“PVDF”), polyethylene, polypropylene, chlorinated polyvinylchloride (“CPVC”), and combinations thereof. Suitable rubbers include,but are not necessarily limited to styrene butadiene rubber (“SBR”).Suitable fibre-reinforced plastics include, but are not necessarilylimited to fiber reinforced plastic. Suitable woods include, but are notnecessarily limited to heat treated woods, weather treated woods, andcombinations thereof. Likewise, the side walls, panels and hinged doorsmay include a painted finish, e.g., powder coat finish including, butnot necessarily limited to a two coat polyester powder-coat finish. Assuch, the chassis 200 side walls, panels and hinged doors may includeany color or combination of colors as desired or as otherwise requiredper legal standards. In addition, one or more side walls, panels ordoors may be constructed from a transparent or translucent material suchas acrylic plastic sheet material for providing viewing windows. Inaddition, the inner surfaces of the chassis 200 side walls, panels andhinged doors may be lined with one or more noise insulating materials toprovide a sound proofed housing and/or heat insulating materials inblanket and/or board form. Suitable blanket type insulating materialsmay comprise fiber reinforced plastic, mineral, plastic fiber, naturalfiber, and combinations thereof. Suitable board type insulatingmaterials may comprise polystyrene, polyurethane, polyisocyanurate, andcombinations thereof.

Suitably, the chassis 200 and ultimately the power system 100 of thisapplication are not necessarily limited in size and weight but may varyaccording to the power requirements for one or more particularoperations. Without limiting the invention, a power system 100 intendedfor hydraulic fracturing operations in locations such as North Americamay have a total weight ranging from about 544.0 kg to about 9,979.0 kg(about 1,200.0 pounds to about 22,000.0 pounds). In addition, a powersystem 100 intended for hydraulic fracturing operations in locationssuch as North America may include a chassis 200 and be provided as anenclosure or housing type structure ranging in size and havingdimensions as listed in Table 1.

TABLE 1 Length cm Width cm Height cm (inches) (inches) (inches) Minimum182.88 (72.0) 121.92 (48.0) 152.40 (60.0) Dimensions: Maximum 457.20(180.0) 177.80 (70.0) 243.84 (96.0) Dimensions:

For purposes of this application, a suitable power system 100 includes ahydraulic power supply system, an electric power supply system and apneumatic power supply system including all hydraulic pump drives, oneor more compressors supplying pneumatic power and one or more electricgenerators necessary to perform a particular fracturing operation whilebeing designed and constructed to withstand an oilfield typeenvironment. With reference to FIG. 11, one suitable power system 100may include at least the following: (1) a primary power source 300, (2)an electric power supply system including an electrical generator 302operatively communicated to the primary power source 300 acting as afeed source of electric power to the frac spread operation, (3) ahydraulic power supply system including (a) a first PTO and hydraulicfeeder pump 304 coupled to the primary power source 300 for frac pump105 operations and (b) a second PTO and hydraulic feeder pump 306coupled to the primary power source 300 for hydraulic power tooloperations, (4) a fuel storage reservoir or fuel tank 308 with closeableinlet and fuel housed therein, (5) one or more storage boxes 309 fortools, supplies, food, beverages, fire extinguishers, and/or otherdesired items, (6) the system controller or “control circuitry”including a control panel 315, (7) a main engine air inlet or intake317, (8) a main air outlet 318, (9) drip pan (not shown), (10) an engineguard (not shown), (11) exhaust system (not shown), (12) cooling system(not shown) (13) lube system (not shown), (14) starting system (notshown), (15) charging system (not shown), (16) hydraulic fluid storageunit or “hydraulic reservoir” of the hydraulic power supply system (notshown), (17) pipe mounts (not shown) within the chassis 200 forreceiving hydraulic lines in fluid communication, (18) a service cabinettype member 320 mounted on the outside of chassis 200 for housing allfuel and hydraulic filters within one self-contained locale for ease ofmaintenance and repair of the same, (19) air intake filters 322 that aresuitably mounted together and accessible for maintenance from groundlevel, (20) one or more light sources (not shown) disposed along theouter surface(s) of the power system 100 and (21) a pneumatic powersupply system compressor 324. The power system 100 is suitably providedwith one or more power transmission outlets or outlet connections forthe transmission of hydraulic fluid, electricity and air pressure fromeach of the hydraulic power supply system, electric power supply systemand pneumatic power supply system to various items located external thepower system 100 requiring hydraulic power and/or electric power and/orpneumatic power. The system controller is electronically communicatedwith the primary power source 300, the electric power supply systemincluding an electrical generator 302, hydraulic power supply system,electric power supply system and pneumatic power supply system of thepower system 100. The power system 100 of this application may becontrolled locally or remotely and automatically or manually, and mayoperate continuously or intermittently. As understood by persons ofordinary skill in the art, electronically communicated data may betransmitted between the system controller and the primary power source300, the electric power supply system including an electrical generator302, hydraulic power supply system, electric power supply system andpneumatic power supply system for controlling and monitoring powersystem 100 operations. The system controller may also be programmed toshut down the power system 100 for scheduled maintenance.

The primary power source 300 and electrical generator 302 may beprovided as a single unit referred to herein as a “gas turbinegenerator,” “electric power generation set,” “generator set” or “genset” provided with or without an enclosure as understood by persons ofordinary skill in the art. In such embodiment, the primary power source300 suitably includes an internal combustion engine, e.g.,compression-ignition engine, spark-ignition engine, operated usinghydrocarbon fuel. A suitable compression-ignition engine includes adiesel engine. A suitable spark-ignition engine includes a gasolineengine. For typical hydraulic fracturing operations, a suitable enginemay have (1) a package weight from about 544.3 kg to about 11,339.8 kg(about 1,200.0 pounds to about 25,000.0 pounds), (2) a rated speed fromabout 650.0 rpm to about 2,200.0 rpm and (3) a rated power from about8.0 hp to about 1,500 hp. A comparable natural gas engine may also beemployed as desired or as otherwise required. Likewise, an electricalgenerator may be employed as a primary power source where desired, e.g.,a permanent installation of the power system 100.

A suitable hydrocarbon fuel tank 308 may range in volume from about 94.6liters to about 3028.3 liters (about 25.0 gallons to about 800.0gallons). For hydraulic fracturing operations, one suitable electricalgenerator 302 may have an electrical output from about 50.0 Hz to about60.0 Hz. Exemplary engines for use as the primary power source 300 mayinclude one of a plurality of commercially available engines, including,but not necessarily limited to engines and generator sets manufacturedby Caterpillar, Inc., Peoria, Ill., U.S.A., such as engines having alower end power rating like the Caterpillar® C4.4, In-line 4, 4-cyclediesel engine up to the Caterpillar® C32 V-12, 4-stroke water-cooleddiesel engine and equivalent. One particular engine that may be employedfor fracturing operations includes a Caterpillar® C7.1 ACERT® Tier 4Diesel Engine.

In an embodiment where the primary power source 300 is provided as partof a generator set, a suitable electrical generator 302 is operationallyconfigured to match the performance and output characteristics of thecorresponding engine. As understood by persons of ordinary skill in theart of generator sets, companies such as Caterpillar, Inc., makeavailable software operationally configured to match a particularelectrical generator 302 with a particular power source 300 byconsidering factors such as operation site conditions, loadcharacteristics and required performance. Gas and diesel generator setsfor use herein are also commercially available from MTU Onsite EnergyCorporation, Mankato, Minn., U.S.A.

The power system 100 of FIG. 11 suitably includes one or more hydraulicfluid pumps, each hydraulic fluid pump corresponding to a separate PTOof the primary power source 300. One hydraulic pump is fluidlycommunicated with the frac pumps 105 provided wherein the hydraulic pumpis operationally configured to provide hydraulic power to start the fracpumps 105 for fracturing operation purposes. The power system 100includes a wholly separate second hydraulic pump suitably provided forpowering hydraulic power tools. Although the hydraulic pumps employed aspart of the embodiment as shown in FIG. 11 are two independent pumps,both pumps may receive oil from a common hydraulic reservoir of thepower system 100. Additional PTOs and hydraulic pumps may be added tothe power system 100 as part of a backup system in a scenario whereeither the first or second hydraulic pump fails.

Each of the members of the power system 100 described above may beoriented and/or located within the chassis 200 perimeter as desired.Although the fuel tank 308 in FIG. 11 is shown resting on the floor 201,in another embodiment the fuel tank 308 may be mounted on the bottom ofthe chassis 200 underneath the floor 201. Storage boxes 309 are suitablyrectangular, e.g., square, and may vary in size according to chassissize limitations. In another embodiment, one or more storage boxes 309may be located external the chassis 200 along one or more side walls ofa chassis 200.

The one or more light sources may include, but are not necessarilylimited to incandescent lighting (including halogen lighting),fluorescent lighting, light emitting diodes (“LED”), and combinationsthereof disposed on each side of the power system 100 and on the chassis200 to provide sufficient illumination of the ambient surroundingsduring low light conditions, inside darkness or during outside darknesshours, e.g., nighttime. LEDs may be provided in the form of LED striplights and/or lamps. Lighting may also be provided in one or more colorsas desired. For example, in addition to one or more light sourcesprovided for illumination purposes, one or more additional light sourcesmay be provided employing differing colors operationally configured asvisual signals as to one or more operating conditions of the powersystem 100. For example, a first light source may be communicated withthe control circuitry and illuminate a first color effective as anindicator that the power system 100 is in operation mode. A second lightsource may be communicated with the control circuitry and illuminate asecond color effective as an indicator that the power system 100 is inan OFF mode. Another light source may be communicated with the controlcircuitry and provided to illuminate a third color as a visual signalthat the power system 100 has malfunctioned or is not operatingaccording to standard operating procedure as programmed. The outersurface of the power system 100 may also include glow in the dark tapedisposed thereon, e.g., to help mark the borders of the power system 100in low light and dark moments. It is further contemplated that the powersystem 100 be provided with one or more audible alarms communicated withthe control circuitry as desired in addition to visual signals oremployed without visual signals.

Regarding the control circuitry, the control panel 315 may include, forexample, a preset program local controller, mounted for ease ofoperation by personnel in local mode. The power system 100 may alsoinclude remote diagnostics to allow one or more components, e.g., themajor components, to be monitored remotely, including, but notnecessarily limited to the primary engine, transmission, hydraulics andPTOs.

Another embodiment of the power system 100 is described with referenceto FIGS. 12-31. In this embodiment, the main support framework includesa platform or floor provided as a rectangular portable support skid(hereafter “skid member 400”) operationally configured to support theremaining support framework and operable components of the power system100 thereon. Suitably, the dimensions and/or one or more materials ofconstruction of the skid member 400 may vary according to the type ofpower system 100 to be provided for one or more operations. As such, theskid member 400 may vary in height, length, width, material thicknessand total weight. To this end, similar sized skid members 400 may varyin weight, for example, a first skid member 400 intended for high stressoperations may be constructed from one or more heavy and/or durablematerials (e.g., steel) compared to a second skid member 400 intendedfor less stressful operating conditions (e.g., aluminum).

As shown in FIG. 13, the skid member 400 of this embodiment includes araised perimeter framework 401 or “sidewall” comprised of individualperimeter members defining the four sides and the height of the skidmember 400. The skid member 400 also includes a bottom floor 403, orbottom surface, and an upper floor 404, or upper surface, spaced apartfrom the bottom floor 403. As shown, the upper floor 404 may include agrid type support surface effective to minimize the weight of the skidmember 400. In addition, a grid type upper floor 404 allows fluids suchas working fluids of the various operable components of the power system100, e.g., fuel, oil, hydraulic fluid, grease, water, due to gravity tobe directed past the upper floor 404 where it is collected and containedby the bottom floor 403. Collected fluids may be removed from the skidmember 400 via a sealable aperture or “master drain 415” disposed alongthe perimeter framework 401. The skid member 400 may include otherdrains as desired. For example, the skid member 400 may include a fueltank drain 416 in fluid communication with the fuel tank 520 via a fluidconduit for the removal of fuel from the fuel tank 520; an engine oildrain 417 in fluid communication with the primary power source 300 via afluid conduit; and a coolant drain 418 in fluid communication with aradiator 514 of the primary power source 300 via a fluid conduit. Inthis embodiment the fuel tank drain 416, engine oil drain 417 andcoolant drain 418 are suitably fitted with hose connected to a ballvalve and all of the drains suitably include a threaded opening forreceiving a threaded drain plug or equivalent therein for sealing eachof the drains. Without limiting the invention, one suitable drain plugincludes an automotive type oil pan drain plug. In one embodiment, thedrains may include 1.27 cm (0.5 inch) weld on half couplings.

In an embodiment intended for fracturing operations, the individualmembers or sections defining the perimeter 401 may be provided as metalbeam members including, but not necessarily limited to channel beams,standard I-beams, angle beams, flat bar beams, tee bar beams, wideflange beams, rectangular tubing, and combinations thereof. In theembodiment of FIG. 13, the individual members or sections defining theperimeter 401 include metal channel beams secured to the upper surfaceof the bottom floor 403 and secured to one another at the four cornersof the skid member 400 via welds, fasteners, and combinations thereof.As further shown, the upper floor 404 is suitably secured to the innersurface 407 of the perimeter framework 401 in a manner to provide asubstantially planar upper surface of the skid member 400 from one endto an opposing end of the skid member 400. In one embodiment, the upperfloor 404 may be secured to the inner surface 407 via welds. In anotherembodiment, the inner surface 407 may include female type cavities forreceiving male members of the upper floor 404 therein. In still anotherembodiment, the upper floor 404 may be secured to the inner surface 407via fasteners including, but not necessarily limited to screws, bolts,pins, and combinations thereof. For fracturing operations, suitablefasteners may be constructed from stainless steel, mild steel,zinc-plated fasteners, and combinations thereof.

Suitably, the skid member 400 includes a planar type bottom side 409providing for a substantially level bottom surface orientation forresting atop one or more substantially level support surfaces such asbare ground, a floor, a roof of a structure, a trailer bed or otherplatform such as a concrete platform or wooden platform or pallet. Inone embodiment, the bottom side 409 may be defined by the perimeterframework 401 as shown in FIG. 14. In another embodiment, the bottomside 409 may be defined by a bottom floor 403 secured to the bottom ofthe perimeter framework 401.

Similar as described above, the skid member 400 of this embodiment mayinclude openings or pockets 405 on one or more sides of the skid member400 for receiving individual forks of a forklift, or other type of lift,in a manner effective to move or transport the power system 100. Theskid member 400 may also include one or more lower lift eyes 410 forlifting and/or transporting the power system 100. As depicted in FIG.13, the skid member 400 may include at least four lift eyes 410 locatednear the corners of the skid member 400 for maintaining the power system100 in a substantially level orientation as the power system 100 isbeing lifted and/or transported. In this embodiment, each of the lifteyes 410 is removably secured to the perimeter framework 401 via aplurality of fasteners 412, e.g., stainless steel, mild steel,zinc-plated nut/bolt type fasteners, and combinations thereof. As such,the perimeter framework 401 is suitably provided with a plurality ofapertures for receiving fasteners there through. For additionalstructural support, backing members 414 such as plate members withapertures there through may be employed opposite corresponding lift eyes410 for receiving distal ends of fasteners there through (see FIGS. 13and 14).

Turning to FIG. 15, the main support framework of this embodiment mayinclude a wall panel frame 420 including a rectangular base 421mountable atop the skid member 400. The wall panel frame 420 may beprovided as a one piece construction or provided as an assembly ofindividual elongated members secured together with fasteners asdescribed herein. The wall panel frame 420 may be constructed frommaterials including, but not necessarily limited to stainless steel,mild steel, fiber reinforced plastic, and combinations thereof. In anembodiment operationally configured for fracturing operations, theelongated members may include carbon structural steel members accordingto ASTM A36.

The wall panel frame 420 may include a box type framework as shown or aportion of a box type framework and one or more wall panels or wallpanel assemblies supported thereon for forming an enclosure of operablecomponents housed therein. One exemplary wall panel assembly 423 isshown in FIG. 16. In one embodiment, the wall panel assembly 423 mayinclude a plurality of planar wall type members releasably attachable tothe wall panel frame 420 via brackets 436 (see FIG. 19) and/or fasteners437 such as rivets, screws, bolts and the like providing the base shellor housing of the power system 100. Suitable fasteners 437 includestainless steel, mild steel, zinc-plated fasteners, and combinationsthereof.

In this embodiment, the wall panel assembly 423 includes various solidsections 425 covering at least part of the wall panel frame 420 andvarious open sections 426 operationally configured to receive doors,louvers, screens, windows, vents or operable equipment for completion ofthe housing for operation of the power system 100. The wall panel(s) ofthe wall panel assembly 423 may also include one or more liner materialsas desired or as otherwise required. Suitably, the arrangement of solidsections 425 and open sections 426 correspond to a particular layout ofoperable components supported on the skid member 400 within the wallpanel assembly 423. Other wall panel configurations are hereincontemplated according to other particular layouts of one or moreoperable components supported on the skid member 400 within the wallpanel assembly 423.

An exemplary layout of main operable components corresponding to thewall panel assembly 423 of FIG. 16 is seen in FIGS. 17 and 18. In thisembodiment the power system 100 includes a primary power source 300, ahydraulic power supply system, an electric power supply system and apneumatic power supply system supported upon a skid member 400, whereinthe primary power source 300 is operationally configured as theexclusive source of power for the hydraulic power supply system,electric power supply system and the pneumatic power supply system. Inthis embodiment as shown, the power system 100 includes at least aprimary power source 300 and electrical generator 302 provided as agenerator set 500, a hydraulic power unit (“HPU”) 509, a hydrocarbonfuel reservoir or fuel tank 520, diesel exhaust fluid (“DEF”) tank 525,compressor 530, first and second battery boxes 528, 529 housingbatteries 532, 533, a first transformer 537, a second transformer 538, afirst cabinet 540 and a second cabinet 543 located below the firstcabinet 540. The first cabinet 540 houses a master circuit breaker 541of the power system 100 and a touch screen control panel 542 of thecontrol circuitry of the power system 100 as well as a plug-in 547 foraccessing primary power source 300 (or “engine 300”) diagnostics. Thesecond cabinet 543 houses a main circuit breaker control panel 544 inelectrical communication with the control circuitry and an assembly ofone or more electric outlets 463 of the control circuitry. As shown, thepower system 100 may also include a remote touch screen control panel546 apart from the power system 100. The remote touch screen controlpanel 546 may be tethered to the control circuitry of the power system100 via electric cable 548 as known in the art or fiber optic cable orcommunicated with the control circuitry via a wireless connection. Theelectric cable 548 may extend any desired distance apart from the powersystem 100. In fracturing operations, an electric cable 548 may includea length as desired. For well site or fracturing operations one suitableelectric cable 548 may include a length up to about 91.4 meters (about300.0 feet). Likewise, wireless communication of the remote touch screencontrol panel 546 may extend a distance up to about 3.22 km (2.0 miles).

An illustration of a completed front side 190 of the wall panel assembly423 of FIG. 16 is illustrated in FIG. 19. In this embodiment, the frontside 190 of the wall panel assembly 423 includes three similarly sizedrectangular open sections 426 fitted with hinged doors 430, 431, 432.Herein, these open sections 426 may be referred to as “doorways.” Eventhough the doorways may vary in size and shape, commonality of thedoorways simplifies the design by requiring use of a single sized hingedstyle door.

As stated above, each of the hinged doors 430, 431, 432 may provideaccess to one or more internal operable components of the power system100. In this embodiment, the first hinged door 430 provides access toHPU 509 including a hydraulic reservoir 510, a hydraulic system gaugedisplay panel 511 and hydraulic reservoir sight glass 512. The secondhinged door 431 provides access to a HPU main hydraulic fluid filter513, radiator or “hydraulic oil cooler 514,” a return hydraulic fluidfilter 516, a kidney loop filter 517 and an air receiver tank 518. Themain hydraulic fluid filter 513 suitably filters hydraulic fluid fromthe hydraulic reservoir 510 in order to minimize the presence ofcontaminants in downstream equipment. The return hydraulic fluid filter516 suitably filters out any contaminants added to the hydraulic fluidfrom any downstream equipment prior to the hydraulic fluid re-enteringthe hydraulic reservoir 510. The kidney loop filter 517 suitably filtershydraulic fluid received from the hydraulic reservoir 510 prior toflowing through the hydraulic oil cooler 514 and re-entering thehydraulic reservoir 510 at a lower temperature for “cooling” or loweringthe temperature of the hydraulic fluid housed in the hydraulic reservoir510.

The third hinged door 432 provides access to the fuel tank 520. In thisembodiment, the first hinged door 430 and the third hinged door 432 areprovided as solid type doors and the second hinged door 431 is providedwith an array of louvers 434 as shown. Suitably, the louvers 434 areoperationally configured to aid in the flow of ambient air into and outfrom the power system 100 including air flow utilized by the hydraulicoil cooler 514. The actual door(s) fitted with louvers may vary inanother embodiment.

FIG. 20 provides a view of the inner surface of the front side 190 ofthe wall panel assembly 423 of FIG. 18. The hinged doors 430, 431, 432and/or the perimeter of the corresponding open sections 426 may includeseals as desired. The hinged doors 430, 431, 432 may also be equippedwith lockless or lockable door handles 438 preventing prohibited entryto the interior of the power system 100. Suitable lockable door handles438 include keyed entry and/or keyless entry type door handles. In oneembodiment, the wall panel assembly 423 may act as a door jamb forreceiving a deadbolt therein. Suitable door handles 438 may includeturnable knobs, turnable handles or a turnable fold out handle 439 andturnable catch 440 for contacting the inner surface of the wall panelassembly 423 when set to a locked position as shown in the embodiment ofFIG. 27.

A completed back side 191 of the wall panel assembly 423, the outersurface and the inner surface, are provided in FIGS. 21 and 22. In thisembodiment, the back side 191 of the wall panel assembly 423 includesfive open sections 426 including three doorways and two smaller opensections. As shown, the first doorway is fitted with a solid hinged door442 and a second doorway is fitted with a hinged door 443 with louvers435. A third doorway is fitted with two equally sized hinged doors 444and 445 and the two smaller open sections are fitted with hinged covers446, 447 as shown. In another embodiment, the hinged doors 444, 445 maybe provided in unequal or differing sizes.

As shown, the hinged doors 442, 443, 444, 445 and hinged covers 446, 447are each fitted with a similar door handle 438 and provide access to oneor more operable components of the power system 100. In this embodiment,the fourth hinged door 442 provides access to the generator set 500, inparticular the engine 300 and its fuel and oil filters provided asstandard equipment of a generator set 500 as understood by the skilledartisan. The fifth hinged door 443 provides access to the generator set500, in particular an electrical generator 302, an air intake 502 and acontrol module or control panel 504 of the primary power source 300. Thelouvers 435 disposed along fifth door 443 aid in the flow of ambient airinto and out from the power system 100 including air flow for coolingthe electrical generator 302. The sixth hinged door 444 provides accessto the first cabinet 540. The seventh hinged door 445 provides access tothe second cabinet 543. The first smaller hinged door 446 providesaccess to a first electric power transmission outlet or “power outlet545” operationally configured to provide electricity for use by one ormore heavy duty items or equipment including, but not necessarilylimited to data vans 110, motor generator units, welders, pumps,compressors, light towers, cellular relay stations, and combinationsthereof. As part of the electric power supply system, the power outlet545 may vary in shape, size, type of connector, voltage and currentrating, e.g., ranging from 20.0 amperes up to 400.0 amperes. Onesuitable power outlet 545 provides a dedicated 240.0 Volt, 60 Hz, 50.0amperes circuit. One suitable power outlet 545 includes a pin and sleeveconnector under the brand name Appleton® available from the EmersonElectric Company, Ferguson, Mo., U.S.A. A suitable power outlet 545 mayalso be flame proof as desired.

The second smaller hinged door 447 provides access to a hydraulic powertransmission outlet or “hydraulic fluid outlet” or “fluid outlet 550,” ahydraulic fluid inlet 555 providing for closed loop circulation ofhydraulic fluid exiting out from the fluid outlet 550, and a pneumaticpower transmission outlet or “compressed air outlet” or “air outlet 556”supplying pneumatic power (e.g., compressed air) to one or morepneumatic power tools 111 or operating as a general compressed airsupply, e.g., for use as an air blower and/or for airing tires and otheritems. In another embodiment, the power system 100 may be provided withtwo or more hydraulic fluid outlets 550, two or more hydraulic fluidinlets 555 and two or more air outlets 556.

In this embodiment, the hydraulic fluid outlet 550 and inlet 555 aresuitably operationally configured to fluidly communicate with varioustypes of fluid conduits and/or fittings as known in the art, e.g.,flange type direct connections and/or fitted with couplings and/orvalves for providing multiple fluid lines. In one suitable embodiment,the outlet 550 and inlet 555 may each be fitted with a diverter valve orT or Y-shape shut-off valve type member, e.g., a stainless steelthreaded Tee member shut-off valve operationally configured to providemultiple hydraulic fluid lines flow out from and back into the powersystem 100. One exemplary Y-shape member for use herein is provided asdescribed in United States Patent Application Publication Number20140311589, entitled “Multi-Port Connector for Fluid Assemblies,” witha publication date of Oct. 23, 2014, the content of which is hereinincorporated by reference in its entirety. Another exemplary valveincludes a gate valve commercially available from W.W. Grainger, Inc.,Lake Forest, Ill., U.S.A. Valves employed at outlet 550 and inlet 555may also include actuators as known in the art. In addition, outlets545, 550, 556 and inlet 555 may be fixed at one or more heights abovethe skid member 400 via a framework or one or more interior framingmembers using one or more brackets, clamps, tie-wraps, threadedfasteners, and combinations thereof as understood by persons of ordinaryskill in the art. The outlets 545, 550, 556 and inlet 555 may also befixed to the wall panel frame 420, e.g., fixed to part of the wall panelassembly 423.

As shown, door 444 is provided with two secondary doors 448, 453thereon. The first door 448 provides access to an emergency stop 461such as a push bottom or pull switch of main breaker 541. The seconddoor 453 provides access to the touch screen control panel 542.Likewise, door 445 is provided with a smaller door 449 operationallyconfigured to provide access to one or more electric outlets 463 forpowering electrical equipment such as power system 100 lights andexternal lights, heater units, mechanical fans, power tools, a data van,and other items requiring electric power such as computers, smartphones,notepads, and the like. Even though doors 448, 453 and 449 are shown asbeing hinged to their respective doors 444, 445 along their upper sides,in another embodiment, one or more of the doors 448, 453 and 449 theright side, left side or bottom side may be hinged to either door 444 or445.

A completed right side 192 of the wall panel assembly 423, the outersurface and the inner surface, are provided in FIGS. 23 and 24. Asshown, the opening 427 (FIG. 16) is provided with main access hingedswing open double doors 450, 451 providing access to the radiator 514 ofthe primary power source 300, compressor 530, batteries 532, 533, DEFtank 525, an air/water separator and air lubricator located under thefirst and second battery boxes 528, 529, and access for filling the fueltank 520. The air/water separator and air lubricator are fluidlycommunicated with the compressor 530 on an upstream side and fluidlycommunicated with air outlet 556 on a downstream side. As understood bythe skilled artisan, the DEF tank 525, injects diesel exhaust fluid intothe engine exhaust 503 where it vaporizing and decomposes to formammonia and carbon dioxide to assist in converting the exhaust toharmless products such as nitrogen and water.

As shown in FIGS. 23 and 24, the doors 450, 451 may be provided withlouvers 452 operationally configured to aid in the flow of ambient airinto and out from the power system 100 including sufficient air flowinto the enclosure for cooling and/or maintaining the internal ambienttemperature at an acceptable upper limit during operation. A completedleft side 193 of the wall panel assembly 423 is provided in FIGS. 25 and26. The opening 428 (FIG. 16) is provided with main access hinged swingopen double doors 454, 455 providing access to the electrical motor 515of the HPU 509 and the transformers 537, 538. As shown, the doors 450,451 may be provided with louvers 456 operationally configured to aid inthe flow of ambient air into and out from the power system 100 includingsufficient air flow into the enclosure for cooling and/or maintainingthe internal ambient temperature at an acceptable upper limit duringoperation of the power system 100. Without limiting the invention, thedouble doors 450, 451, 454, 455 may include turnable lockable doorhandles as known for use with double swing open double doors, including,but not necessarily limited to turnable lockable handles 458 as shown.

The power system 100 may include a multi-panel or single-panel roof 460securable to the upper portion 422 of the wall panel frame 420 in amanner effective to cover the top of the wall panel frame 420 providinga removable enclosure for the operable components of the power system100 housed therein. Suitably, the roof 460 includes one or moreapertures or cut-out sections in fluid communication with the ambientenvironment. In particular, the one or more apertures or cut-outsections are operationally configured to receive part of the engine airintake 502 and engine exhaust 503 there through. As seen in FIG. 18, theengine exhaust 503 may include an upward facing outlet member 506 withan exhaust rain cap 507 hingedly attached thereto. A clamp 508 may alsobe employed for securing the engine exhaust 503 to the roof 460. Theroof 460 may also include vents and the like to aid in the flow ofambient air into and out from the power system 100. Vents may alsoinclude open/shut covers to prevent rain and other foreign materialsfrom entering the power system 100. In another embodiment, the roof 460may be provided as a sloped roof from about 1.0 degree up to about 10.0degrees effective for water such as rain and melting snow to easily runoff the roof 460 eliminating the possibility of standing water collectedatop the roof 460. As such, the upper portion 422 of the wall panelframe 420 may be operationally configured to accommodate a sloped roof,i.e., upper portion 422 having a multi-level height. In anotherembodiment, the roof 460 may include a first end higher than a secondend for providing an upper sloped surface there between.

As shown in FIG. 28, the removable enclosure 600, i.e., the wall panelframe 420, wall panel assembly 423 and roof 460 may be provided as onepiece construction or otherwise assembled together prior to beingsecured to the skid member 400 supporting at least some operablecomponents thereon whereby other operable components may be installedafter the removable enclosure is secured to the skid member 400. In suchembodiment, the power system 100 may include one or more upper lift eyes411 secured to the upper portion 422 of the wall panel frame 420 at ornear the corners for maintaining the power system 100 in a substantiallylevel orientation as the removable enclosure is being transported onand/or off a skid member 400 (see Directional Arrows A and B). Inanother embodiment, the upper lift eyes 411 may be secured to the wallpanel assembly 423. In another embodiment, the upper lift eyes 411 mayalso be used for transporting and/or lifting the complete power system100 including the skid member 400.

In an embodiment purposed for fracturing operations, a power system 100may include an enclosure including a wall panel assembly 423 and roof460 constructed from plastic, fiber reinforced plastic, stainless steel,mild steel, galvanized steel, and combinations thereof with or without acorrosion resistant powder-coated paint finish. Likewise, the variousdoors of the front side 190 and back side 191 of the wall panel assembly423 may be constructed from plastic, fiber reinforced plastic, stainlesssteel, mild steel, galvanized steel, and combinations thereof with orwithout a corrosion resistant powder-coated paint finish. It is alsocontemplated that the outer surface of the wall panel frame 420 and/orwall panel assembly 423 may include protective guard membersoperationally configured to protect against handling damage of the outersurface of the power system 100, e.g., rubber guard members placed alongthe outer corners of the power system 100.

In an embodiment purposed for fracturing operations, a power system 100as described with reference to FIGS. 12-31 may be provided with thefollowing dimensions as listed in Table 2 below.

TABLE 2 Meters Feet Power System 100 Height: about 2.51 about 8.255Power System 100 Length: about 3.91 about 12.84 Power System 100 Width:about 2.57 about 8.42 Skid Member 400 Height: about 0.3 about 1.0 HingedCovers 446, 447 Width: about 0.31 about 1.02 Hinged Doors 430, 431, 432Height: about 1.97 about 6.46

Turning to FIGS. 29 and 30, a suitable generator set 500 for use hereinmay be provided as a standalone modular unit including a modularframework including, but not necessarily limited to a skid member 501constructed from steel tubing, i.e., square tubing or box tubing, asknown the art of generator sets securable to the skid member 400 viafasteners such as clamps and/or nut/bolt type fasteners as describedabove. Likewise, the HPU 509 may be provided as a standalone modularunit including a modular framework including, but not necessarilylimited to a skid member 523 securable to the skid member 400 viafasteners such as nut/bolt type fasteners as described above. In onesuitable embodiment, the HPU 509 (1) is operationally configured tostart up to four frac pumps 105 remotely simultaneously using a startbutton or the like, (2) includes adjustable circuits to provide primaryor back-up hydraulic power to run sand-handling equipment (e.g., sandkings, t-belts), (3) employs SMART technology for monitoring HPU 509performance and oil conditions.

In addition, the transformers of the power system 100 (e.g., a firsttransformer 537, a second transformer 538) may also be provided on amodular framework securable to the skid member 400. Likewise, the firstcabinet 540, second cabinet 543 and their contents (e.g., master circuitbreaker 541 and main circuit breaker control panel 544) may also beprovided on a modular framework securable to a framework of the powersystem 100. Such modularity of the various operable components suitablydecreases total manufacturing time allowing the power system 100 to beeasily assembled. In addition, modularity improves the maintainabilityof the various operable components of the power system 100. Moreover,the modularity of the various operable components is effective for thepower system 100 to include the operable components in a plurality oflayouts on a single platform or on multiple platforms at both temporaryand permanent installations.

With reference to the flowchart 700 of FIG. 31, the power system 100 ofthis application is operationally configured to provide hydraulic power,electric power and pneumatic power simultaneously, all of which isdriven exclusively by a single power source such as a single generatorset 500, beginning with operation of the engine 300. In particular, fuelstored in the fuel tank 520 is fluidly communicated to the engine 300 ofthe generator set 500 via line 580 for compression-ignition orspark-ignition depending on the type of engine 300 and fuel employed.Likewise, the batteries 532, 533 supply electric current to the engine300 via line 570 to start the engine 300 as understood in the art.Although the power system 100 may be built to scale, a power system 100as shown in FIGS. 17 and 18 operationally configured for fracturingoperations may employ a generator set 500 such as the Caterpillar® C7.1diesel generator, 200.0 ekW, 60.0 Hz, 1800.0 rpm 480.0 Volts orequivalent. Another exemplary generator set 500 may include model numberQSB7 commercially available from Cummins Power Systems, Minneapolis,Minn., U.S.A. As understood by the skilled artisan, a generator set 500for use herein may be equipped with (1) an air inlet system, (2) acontrol system, (3) a cooling system, (4) an exhaust system, (5)flywheels and a flywheel housing, (6) a fuel system, (7) at least onegenerator and related attachments, (8) a lube system, (9) a mountingsystem, (10) one or more power take-offs and a crankshaft pulley, (11) atorsional vibration damper and guard, (12) lift eyes, (13) a batteryswitch disconnect, (14) an exhaust temperature sensor, (15) flexiblefuel lines, (16) a dipstick, (17) a coolant recovery tank and (18) ajacket water heater.

In regard to the an electric power supply system, an exemplary generatorset 500 may be effective for supplying 480.0 Volts of electric currentto the master circuit breaker 541 via line 565. The first and secondtransformers 537, 538 of the electric power supply system are suitablyeffective to transform line voltage to one or more voltages suitable forpowering equipment and other devices external the power assembly 100.For example, in this embodiment the first transformer 537 receives 480.0Volts of electric current from the master circuit breaker 541 via line566 and transforms or steps down the voltage from 480.0 Volts to 240.0Volts. The second transformer 538 receives 240.0 Volts of electriccurrent from the first transformer 537 via line 568 and steps down thevoltage from 240.0 Volts to 120.0 Volts. In another embodiment, thepower system 100 may be provided with a single transformer. In yetanother embodiment, three or more transformers may be employed as partof the power system 100.

In this embodiment, the power outlet 545 may make use of the 240.0 Voltssupply of the first transformer 537 via line 572. In addition, a secondelectric power transmission outlet provided as one or more electricoutlets 463 may make use of the 240.0 Volt supply of the firsttransformer 537 via line 571 and one or more other electric outlets 463may make use of the 120.0 Volts supply of the second transformer 538 vialine 569. In other words, one or more electric outlets 463 may includeone or more 120.0 Volt outlets, one or more 240.0 Volt outlets, andcombinations thereof. In one embodiment, the electric outlets 463 maycomprise two 240.0 Volt outlets and eight 120.0 Volt outlets. It is alsocontemplated that one or more 480.0 Volt outlets be provided making useof the 480.0 Volt directly from the master circuit breaker 541. As such,in another embodiment, the power system 100 may include one or moreelectric outlets including one or more 120.0 Volt outlets, one or more240.0 Volt outlets, one or more 480.0 Volt outlets, and combinationsthereof.

In regard to the hydraulic power supply system, the electrical motor 515receives 480.0 Volts of electric current from the master circuit breaker541 via line 567 for powering the electrical motor 515, which in turnpowers the hydraulic pump 519 for pumping hydraulic fluid out from thehydraulic reservoir 510 through a main hydraulic fluid filter 513 andout through the hydraulic fluid outlet 550 via line 575 to a downstreamdestination such as one or more frac pumps 105 and/or one or morehydraulic power tools 108 at a desired rate, e.g., up to about 24.13 MPaat 4.73 L/s (about 3500.0 psi at 75.0 gallons per minute). The hydraulicfluid is returned from one or more frac pumps 105 and/or one or morehydraulic power tools 108 in a closed loop configuration and enters thepower system 100 through a hydraulic fluid inlet 555 into line 576 andthrough the hydraulic fluid filter 516 before returning to the hydraulicreservoir 510.

In regard to the pneumatic power supply system, the electrical motor 515further powers the compressor 530 via a hydraulic line 578 by providingpressurized hydraulic fluid to drive the compressor 530. In anotherembodiment, the hydraulic pump 519 may comprise two pumps in series, amain pump as described above and a smaller pump. In such embodiment, thesmaller pump is operationally configured to power the compressor 530 viaa hydraulic line 578 by providing pressurized hydraulic fluid to drivethe compressor 530. Once powered, the compressor 530 is operationallyconfigured to convey compressed air, for example, at 1.05 cmm at 0.69MPa (about 37.0 cfm at 100.0 psi) to the air outlet 556 via line 579. Inan embodiment of the power system 100 suitable for fracturingoperations, the maximum pressure is about 1.03 MPa (about 150.0 psi).Each of the fluid lines and electrical lines may include one or moreouter insulated materials and/or one or more outer protective coverssuch as spiral protective wrapping known in the art. The compressor 530of the power system 100 eliminates the need for truck carriedcompressors typically provided for pneumatic power tools on work sites.

The power system 100 may also be provided with a full data telemetrysystem or telemetry package 610, e.g., a bolt on unit mounted on theroof 460, operationally configured to read all data of the power system100 via wireless network, cellular network, satellite network, andcombinations thereof. In particular, a suitable telemetry package 610provides (1) remote monitoring of one or more power system 100parameters, (2) system upgrades of the power system 100 includingsoftware updates that may be performed remotely and (3) data including,but not necessarily limited to tracking of the location, performance andoperational status of the power system 100. If a user of the powersystem 100 is at a location out of range for remote operation, thetelemetry package 610 is operationally configured to save or store datafor retrieval at a later time.

The power system 100 may also be provided with one or more sensors formonitoring various operating conditions of the power system 100. Forexample, the power system 100 may include up to four hundred (400) ormore sensors, e.g., the HPU 509 may be provided with up to twenty-two(22) sensors for monitoring the operating status of the HPU 509 and theengine 300 may be provided with over three hundred (300) standardsensors from the manufacturer for monitoring engine 300 performance—allof which may be communicated to the control circuitry of the powersystem 100, which in turn is in electric communication with one or morecontrol centers. For example, sensor readings may be viewed via thetouch screen control panel 542 or elsewhere, e.g., via monitors in adata van 110. For example, one or more remote meters may be installed atone or more locations around the well site, e.g., inside a data van 110,to monitor and record engine 300 hours, HPU 509 hours, engine 300temperatures, engine 300 pressures, engine 300 rpm, and other engine 300parameters, and send the information to end user maintenance managementsoftware or the like. Hydraulic pump pressure and pump rate may bemonitored, recorded and sent to any computer or the like as desired orotherwise programmed. A data van 110 or other control center may beoperationally configured to remotely start and stop the power system 100and/or each frac pump 105 from a remote location (e.g., a control centerfor the power system 100) in addition to starting and stopping each fracpump 105 locally. During fracturing operations, personnel may providereal-time data to customers or other parties of interest. Once afracturing operation is stopped or otherwise completed, personnel mayproduce detailed reports regarding the operation and an accounting foreach item or component making up the total cost of the operation.

In view of the above discussion, a process for extracting oil and gas byhydraulic fracturing represents another aspect of the present invention.In one implementation, an entity such as an operations vendor, i.e., afracturing operations company and its personnel, enter an intended wellsite and rig up a frac spread utilizing the present system equipmentincluding the power system 100. Although not limited as to locationand/or orientation, a power system 100 may be placed in an easilyaccessible area near a bank of frac pumps 105 and a data van 110, e.g.,within about 2.0 meters of the nearest frac pump 105 and within about5.0 meters of a data van 110. Depending on the size of the well site andthe layout of specific equipment and the quantities of equipment neededto be powered, a second power system 101 may be employed as part of thefrac spread as shown in FIG. 4. For example, a well site includingmultiple banks of frac pumps 105, 106 may each include a power system100 and 101 dedicated for use with a particular bank of frac pumps 105or 106.

Once the power system 100 is set in place at a desired location,preferably a substantially level surface, the power system 100 may befluidly connected to the most proximal frac pump 105 via a fluid conduitassembly 117 as described above. Subsequent frac pumps are suitablyinterconnected or “daisy chained” together with additional hydraulicline and isolation valves known in the art in a closed loopconfiguration with a return flow line 121 operationally configured toconvey hydraulic fluid back to the hydraulic reservoir 510 of the powersystem 100. Suitable isolation valves include, but are not necessarilylimited to high pressure two-way ball valves commercially available fromDalton Bearing & Hydraulic, LLC, Blaine, Tenn., U.S.A., e.g., seetwo-way ball valve item number 242-163-D.

In one mode of operation utilizing the power system 100 of FIG. 17,personnel initially start the engine 300, which then starts and runs theelectrical generator 302 of the generator set 500. Each of the fracpumps 105 are suitably turned on in subsequent order starting with thefrac pump 105 located nearest the power system 100. For example, oncethe power system 100 is operating, a first isolation valve 103controlling the flow of hydraulic fluid from the power system 100 to thefirst frac pump 105, i.e., the frac pump 105 located nearest the powersystem 100, may be opened either manually or remotely allowing hydraulicfluid to flow to a hydraulic starter of the frac pump 105 for activatingthe frac pump 105, i.e., for activating the engine of the frac pump 105.Once the first frac pump 105 is started, the first isolation valve 103may be shut off and the process repeated with each subsequent frac pump105 until all the frac pumps in series are turned on and operational forpumping fracturing fluid into a well. The opening or closing of theisolation valves may be performed locally or remotely via electrical,hydraulic or pneumatic actuators. Because isolation valves can be set toany position between fully open and fully closed, valve positioners maybe employed to ensure each valves attains the desired degree of opening.Air-actuated valves are commonly used because of their simplicity, asthey only require a compressed air supply, whereas electrically-operatedvalves require additional cabling and a switch gear,hydraulically-actuated valves required high pressure supply and returnlines for the hydraulic fluid.

The invention will be discussed with reference to the followingnon-limiting examples, which are illustrative only and not intended tolimit the present invention to a particular embodiment.

Example 1

In a first non-limiting example, a system as shown in FIG. 2 is providedas part of a frac spread. Each frac pump 105 includes a diesel-poweredengine and hydraulic pump. Collectively, the frac pumps 105 providesufficient pressure into a wellbore for the injection and movement offracturing fluid, e.g., water, proppants, and chemical additives, up toseveral hundred meters of earth and rock. The power system 100 and fracpumps 105 are operationally configured to operate over a wide range ofpressures and injection rates and can operate at about 100.0 MPa(15,000.0 psi) or higher and 265.0 L/s (100.0 barrels per minute) orhigher. The power needed for hydraulic fracturing operations may exceed20.0-30.0 megawatts.

The generator set 500 may be powered to supply (1) hydraulic fluid tothe frac pumps 105, (2) electric power to one or more items of the fracspread, e.g., data van 110, one or more lighting towers 115 and (3)pneumatic power to one or more pneumatic power tools or items requiringcompressed air. Electric power and/or pneumatic power may be madeavailable before activation of any frac pumps 105, during fracturingdownhole and after the frac pumps 105 are shut down.

The size of each frac pump 105 may depend on various factors such as theoverall pumping requirements at the well site, e.g., in terms of pumpingpressure and pumping rate. For typical fracturing operations in NorthAmerica, each frac pump 105 may have the following performancespecifications: (1) maximum pressure of about 137.9 MPa (about 20,000.0psi), (2) minimum pump rate of about 321.9 liters per minute (about 2.7bpm); (3) maximum pump rate of about 2253.6 liters per minute (about18.9 bpm; and (4) hydraulic horsepower ranging from about 2000.0 hhp toabout 3000.0 hhp, although this range can vary considerably.

Example 2

In a second non-limiting example, a frac spread similar as shown in FIG.1 is replaced by incorporating a frac spread comprising the system asshown in FIG. 4. The frac spread of FIG. 1 is a 50,000 hydraulichorsepower (“HHP”) frac spread. Just over one half of the cost of a fracspread of this size typically goes for construction of the frac pumps105 and trailers—about 30,000,000.00 U.S. dollars at the time of filingof this application. A typical rule of thumb for vehicles and personnelis one vehicle for each 1,000 HHP and two persons for each 1,000 HHP.Thus, a 50,000 HHP frac spread will comprise about fifty (50) vehiclesand will be crewed by about ninety (90) to one hundred (100) persons.About half of these individuals work directly with the fracturingoperation. The other personnel work on jobs such as wireline, water,proppant, and coiled tubing. The actual number of persons on-site canvary depending on several factors including the particular phase oroperation the job is in at a given moment, how many people the operatorhas on site, and what ancillary equipment is deployed around the wellsite.

At the time of this application, by implementing the system of FIG. 4,the following benefits may be realized: (1) reduce capital expenditures,e.g., cost savings may range from about 100,000 U.S. dollars to about350,000 U.S. dollars per fracturing operation, normalized for a periodof one month operational activities, (2) decrease the total number ofassets, (3) reduce maintenance facilities, (4) reduce maintenancepersonnel, (5) free up personnel to work on primary on-site equipment,(6) decrease time on governmental compliance for tractors, (7) decreasethe number of commercial drivers on-site, (8) reduce tractor spare partsinventory, (9) reduce tractors fuel usage from otherwise excessive idletimes, (10) decrease maintenance costs of tractors, (11) decrease wastedfuel from excessive idle times on frac pumps 105, (12) provideredundancy (true back-up) options in the field, lowering Non-ProductiveTime (“NPT”), (13) increase environmental stewardship, (14) reducerental cost associated with lighting, (15) decrease the number ofpersonnel on-site for operating small engines, (16) reduce time on smallengine refueling, (17) redirect personnel to primary equipment and awayfrom small engine maintenance, (18) eliminate rental generator setsemployed for data van 110 primary or backup power, (19) eliminate costsand complexity for redundant power options for sand-handling equipment,(20) reduce health, safety, environment (“HSE”) risks by eliminating orreducing on-site refueling of equipment, (21) remove tasks thatotherwise put personnel in high risk and moderate risk areas, (e.g., redzones, yellow zones), (22) decrease personnel required to start fracpumps 105. In this example, the number of personnel on-site will bereduced by a range of about ten (10.0) to about thirty (30.0) percentduring fracturing operations.

It is believed that present application and advantages will beunderstood by the forgoing description. Persons of ordinary skill in theart will recognize that many modifications may be made to the presentapplication without departing from the spirit and scope of theinvention. The embodiment(s) described herein are meant to beillustrative only and should not be taken as limiting the invention,which is defined in the claims.

I claim:
 1. A power system including: a platform supporting a primarypower source, a hydraulic power supply system, an electric power supplysystem and a pneumatic power supply system thereon, wherein the primarypower source is an exclusive source of power for the hydraulic powersupply system, the electric power supply system and the pneumatic powersupply system and wherein the power system includes one or morehydraulic fluid outlets for the transmission of pressurized hydraulicfluid out from the power system and one or more hydraulic fluid inletsfor re-entry of the pressurized hydraulic fluid back into the powersystem.
 2. The power system of claim 1 wherein the pressurized hydraulicfluid transmitted out from the power system via the one or morehydraulic fluid outlets is transmitted to one or more items locatedexternal the power system requiring hydraulic power, wherein theelectric power supply system includes one or more electric outletconnections for the transmission of electricity out from the powersystem to one or more items located external the power system requiringelectric power and wherein the pneumatic power supply system includesone or more compressed air outlet connections for the delivery ofcompressed air out from the power system to one or more items externalthe power system requiring compressed air.
 3. The power system of claim2 wherein the one or more electric outlet connections are selected fromthe group consisting of 120.0 Volt outlets, 240.0 Volt outlets, 480.0Volt outlets, and combinations thereof including one or more 120.0 Voltelectric outlet connections, one or more 240.0 Volt electric outletconnections and one or more 480.0 Volt electric outlet connections. 4.The power system of claim 1 wherein the hydraulic power supply systemincludes a hydraulic power unit including an electrical motor, ahydraulic fluid pump, a hydraulic fluid storage reservoir, a mainhydraulic fluid filter, a hydraulic oil cooler, a return hydraulic fluidfilter and a kidney loop filter.
 5. The power system of claim 4including an enclosure secured to the platform operationally configuredto house the hydraulic power supply system, the electric power supplysystem and the pneumatic power supply system wherein the enclosureincludes a roof and a plurality of doors, the roof and the plurality ofdoors having openings for ambient air flow into and out from the powersystem.
 6. The power system of claim 1 wherein the platform includes aportable support skid.
 7. The system of claim 6 wherein the portablesupport skid includes a perimeter sidewall, a bottom surface and anupper surface spaced apart from the bottom surface, wherein the uppersurface is operationally configured to support the primary power source,hydraulic power supply system, electric power supply system andpneumatic power supply system thereon and allow gravitational fluid flowto be captured and contained by the bottom surface.
 8. The power systemof claim 7 wherein the perimeter sidewall includes a drain for removalof fluid contained by the bottom surface.
 9. The power system of claim 1including an enclosure secured to the platform operationally configuredto house the hydraulic power supply system, the electric power supplysystem and the pneumatic power supply system.
 10. The power system ofclaim 1 wherein the primary power source includes an internal combustionengine operatively communicated to the hydraulic power supply system,electric power supply system and pneumatic power supply system.
 11. Thepower system of claim 1 wherein the power system includes a mastercircuit breaker and a generator set in electrical communication with themaster circuit breaker.
 12. The power system of claim 1 furtherincluding control circuitry in operable communication with the primarypower source, the hydraulic power supply system, the electric powersupply system, and the pneumatic power supply system.
 13. The powersystem of claim 12 further including one or more control panels inelectrical communication with the control circuitry.
 14. The powersystem of claim 13 wherein the one or more control panels may beselected from the group consisting of control panels hard wired directlyto the power system, control panels remotely tethered to the powersystem via electrical transmission lines, control panels in wirelesscommunication with the control circuitry, and combinations thereof. 15.The power system of claim 1 wherein the power system includes one ormore fuel storage reservoirs in fluid communication with the primarypower source, wherein the primary power source includes a first powertake off and a second power takeoff and wherein the hydraulic powersupply system includes two hydraulic fluid pumps in series.
 16. Thepower system of claim 1 further including a removable enclosure housingthe primary power source, the hydraulic power supply system, theelectric power supply system and the pneumatic power supply systemtherein, wherein the hydraulic power supply system includes a hydraulicpower unit and wherein the removable enclosure includes a first doorproviding access to the hydraulic power unit and a second door providingaccess to the one or more hydraulic fluid outlets and the one or morehydraulic fluid inlets.
 17. A system for fracturing operations at a wellsite including: one or more high pressure fracturing pumps operationallyconfigured to inject fluid into one or more wells at the well site; anda portable power system including a platform supporting a primary powersource, a hydraulic power supply system, an electric power supply systemand a pneumatic power supply system thereon, wherein the portable powersystem includes (1) one or more outlet connections for the transmissionof pressurized hydraulic fluid to the one or more high pressurefracturing pumps, (2) one or more outlet connections for thetransmission of electricity to one or more items external the portablepower system requiring electric power and (3) one or more outletconnections for the transmission of air pressure to one or more itemsexternal the portable power system requiring pneumatic power and whereinthe portable power system includes one or more hydraulic fluid inletconnections for re-entry of the pressurized hydraulic fluid back intothe portable power system; wherein the primary power source is anexclusive source of power for the hydraulic power supply system, theelectric power supply system and the pneumatic power supply system; andwherein the hydraulic power supply system is an exclusive power sourcefor the one or more high pressure fracturing pumps.
 18. The system ofclaim 17 wherein the portable power system includes one or morehydrocarbon fuel storage reservoirs in fluid communication with theprimary power source, and wherein the primary power source isoperationally configured to convert hydrocarbon fuel to electricity forpowering the hydraulic power supply system, the electric power supplysystem and the pneumatic power supply system.
 19. A modular power systemincluding: a first modular platform supporting a first modular primarypower source, a hydraulic power supply system including a first modularhydraulic power unit, an electric power supply system including one ormore electric outlet connections and one or more modular transformers incommunication with the one or more electric outlet connections and apneumatic power supply system thereon, wherein the primary power sourceis an exclusive source of power for the hydraulic power supply system,the electric power supply system and the pneumatic power supply systemand wherein the modular power system includes one or more hydraulicfluid outlet connections for the delivery of pressurized hydraulic fluidout from the modular power system and one or more hydraulic fluid inletconnections for re-entry of the pressurized hydraulic fluid back intothe modular power system.
 20. The modular power system of claim 19including a second modular platform operationally configured to supportthe first modular primary power source at a first location on the firstmodular platform and a third modular platform operationally configuredto support a hydraulic power unit of the hydraulic power supply systemat a second location on the first modular platform, wherein the secondmodular platform and third modular platform may each be secured to thefirst modular platform via fasteners.